[SIS6] Industrial Application of Functional Materials

[16C-SIS6-02] Additive Manufacturing of High-efficient Monolithic Fe6.5Si Electric Sheet Stacks

*K. Reuter¹, T. Simon¹, I. Lindemann-Geipel¹, T. Mix¹, T. Studnitzky¹, C. Zhong¹, T. Weissgärber^1,2 (1.Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Germany, 2.TUD Dresden University of Technology, Faculty Mechanical Engineering, Institute of Material Science, Chair Powder Metallurgy, Germany)

Keywords:additive manufacturing, soft magnetic materials, screen printing

Energy-efficient electric motors are crucial for the progress of electromobility. Soft magnetic materials with a high silicon content, such as Fe6.5Si, offer the possibility of high electrical resistance, relatively high saturation magnetization and comparatively low power losses. However, due to the brittleness of Fe6.5Si, this material cannot be processed using conventional manufacturing methods (such as stamping). The 3D screen printing process enables the production of thin Fe6.5Si electrical sheets in end geometry. But conventional methods for stacking are not suitable when dealing with those brittle sheets. For the first time, we are demonstrating the production of monolithic electrical steel stacks by alternately printing soft magnetic and ceramic layers on top of each other. These stacks are then densified in a joint heat treatment process (co-sintering). The material and magnetic properties of the stacks will be discussed in dependence on the sintering parameters and the powder properties.